# US 9,873,149 B2 · Caliper casting device, core and mold used in caliper casting device, caliper for disc brake, and manufacturing method thereof > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,873,149 B2 - Document ID: US9873149B2 - Status: Granted - Kind: B2 - Application number: 14/772,964 - Filed: 2014-03-14 - Published: 2016-06-30 - Granted: 2018-01-23 - Earliest claimed: 2013-09-20 - Assignees: Akebono Brake Industry Co., Ltd. - Applicants: Akebono Brake Industry Co., Ltd. - Inventors: Takayuki Arai; Iseto Suzuki; Jungo Masuda - Web page: https://patentgrep.com/patent/US9873149B2 ## CPC - B22C 9/101: {Permanent cores} - B22C 9/064: {Locating means for cores} - B22C 9/108: {Installation of cores} - B22C 9/22: Moulds for peculiarly-shaped castings - B22D 17/24: Accessories for locating and holding cores or inserts - B22D 25/02: by its peculiarity of shape; of works of art {(cylinders, pistons B22D15/02)} - F16D 65/0068: {Brake calipers} - F16D 65/18: adapted for drawing members together {, e.g. for disc brakes} - F16D 2055/0016: {Brake calipers} - F16D 2200/003: Light metals, e.g. aluminium - F16D 2250/0015: around inserts - B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B) - B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22) - F16D: COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES ## Abstract A technique is provided capable of favorably preventing generation of a shrinkage cavity in solidification of molten metal poured into a casting mold, and increasing accuracy of an assembling position of a core to a mold, in casting a caliper. A caliper casting device for casting a caliper for a disc brake including a cylinder into which a piston is fitted, and a rotor housing surface that defines a space for housing a disc rotor, includes: a mold; and a core placed in the mold, the mold having a rotor housing surface forming portion that forms a part of the rotor housing surface after casting, and the core being positioned and held in the rotor housing surface forming portion during casting, and forming a part of the rotor housing surface together with the rotor housing surface forming portion after casting. ## Claims ### Claim 1 A caliper casting device for casting a caliper for a disc brake including a cylinder into which a piston is fitted, and a rotor housing surface that defines a space for housing a disc rotor, comprising; a mold; and a core placed in the mold, the mold having a rotor housing surface forming portion that is configured to form a part of an inner wall surface of the rotor housing after casting, and the core being positioned and held in the rotor housing surface forming portion during casting, and forming a part of the inner wall surface of the rotor housing together with the rotor housing surface forming portion after casting, wherein: a positioning groove that positions and holds the core is formed in the rotor housing surface forming portion, the core includes a cylinder forming portion that forms the cylinder after casting, and a core print portion coupled to the cylinder forming portion, and the core print portion has a fitted portion that can be fitted in the positioning groove and forms the rotor housing surface together with the rotor housing surface forming portion after casting. ### Claim 2 (depends on 1) The caliper casting device according to claim 1, wherein: the positioning groove includes a first groove, and a second groove intersecting the first groove, and the fitted portion is fitted in the first groove and the second groove. ### Claim 3 (depends on 2) The caliper casting device according to claim 2, wherein the first groove and the second groove are linear grooves and perpendicular to each other. ### Claim 4 (depends on 1) The caliper casting device according to claim 1, wherein: the core print portion further includes a stopper portion that is provided at an end of the fitted portion and is wider than the positioning groove, and the stopper portion has a stepped surface that abuts against a side surface intersecting the positioning groove in the rotor housing surface forming portion when the fitted portion is fitted in the positioning groove. ### Claim 5 (depends on 1) The caliper casting device according to claim 1, wherein the core has a plurality of the cylinder forming portions, and each of the cylinder forming portions is coupled by the core print portion. ### Claim 6 (depends on 1) The caliper casting device according to claim 1, wherein the rotor housing surface forming portion has higher thermal conductivity than the core. ### Claim 7 (depends on 1) A caliper for a disc brake that is casted using a caliper casting device according to claim 1. ### Claim 8 A core used in a caliper casting device for casting a caliper for a disc brake including a cylinder into which a piston is fitted, and a rotor housing surface that defines a space for housing a disc rotor, wherein the core is positioned and held, during casting, in a rotor housing surface forming portion of a mold in the caliper casting device, which rotor housing surface forming portion is configured to form a part of an inner wall surface of the rotor housing surface after casting, and wherein the core forms a part of the inner wall surface of the rotor housing together with the rotor housing surface forming portion after casting, and wherein: a positioning groove that positions and holds the core is formed in the rotor housing surface forming portion, the core includes a cylinder forming portion that forms the cylinder after casting, and a core print portion coupled to the cylinder forming portion, and the core print portion has a fitted portion that can be fitted in the positioning groove and forms the rotor housing surface together with the rotor housing surface forming portion after casting. ### Claim 9 A mold used in a caliper casting device for casting a caliper for a disc brake including a cylinder into which a piston is fitted, and a rotor housing surface that defines a space for housing a disc rotor, wherein the mold has a rotor housing surface forming portion that is configured to form a part of an inner wall surface of the rotor housing after casting, and can position and hold a core that forms a part of the inner wall surface of the rotor housing together with the rotor housing surface forming portion after casting, and wherein: a positioning groove that positions and holds the core is formed in the rotor housing surface forming portion, the core includes a cylinder forming portion that forms the cylinder after casting, and a core print portion coupled to the cylinder forming portion, and the core print portion has a fitted portion that can be fitted in the positioning groove and forms the rotor housing surface together with the rotor housing surface forming portion after casting. ### Claim 10 A manufacturing method for manufacturing a caliper for a disc brake including a cylinder into which a piston is fitted, and a rotor housing surface that defines a space for housing a disc rotor, wherein: the caliper casting device includes a mold having a rotor housing surface forming portion that is configured to form a part of an inner wall surface of the rotor housing after casting, and a core placed in the mold, and the manufacturing method comprises the steps of: positioning and holding the core in the rotor housing surface forming portion to place the core in the mold; and pouring molten metal into the mold in which the core is placed, the core forming a part of the inner wall surface of the rotor housing together with the rotor housing surface forming portion after casting, wherein: a positioning groove that positions and holds the core is formed in the rotor housing surface forming portion, the core includes a cylinder forming portion that forms the cylinder after casting, and a core print portion coupled to the cylinder forming portion, and the core print portion has a fitted portion that can be fitted in the positioning groove and forms the rotor housing surface together with the rotor housing surface forming portion after casting. ### Claim 11 (depends on 10) A caliper for a disc brake manufactured with a manufacturing method according to claim 10.